Anyone out there building a Revolution II or a Spacewalker II? Would like to hear your experiences and costs. Is there a support group out there? I found a yahoo group but there does not seem to be much activity. Thanks.
Two hinge arms per assembly is what my plans show.I haven't constructed the ailerons yet, but I'm leaning towards adding a re-inforcing washer tack welded on each side of the hinge arm and bushing the aileron hinge arms. I can email you a sketch if you like.
Early ailerons only used one hinge arm per assembly, later ones used two back to back. The early single hinge point would certainly wear quickly. Theres a comment pertaining to this in the spacewalker.org site (I think).
I actually thought about the alignment issue. I was planning on using a 6-7 foot rod to ensure proper alignment. I was more interested in what size/type of bearings people were using.The ball bearing hinge arms are very good, but I think overly complicated. If the hinge arms aren't in alingment, then you will still end up with binding of the aileron anyway.
I've seen one aileron that had quite a twist in the aileron spar so it would never operate freely anyway (it was still under construction and didn't have the leading edge ply cell attached, so it may have come good once it was clamped down).